For some entrepreneurs, the economic crisis of 2015-2016 was a real blow to business, while others, on the contrary, even won. I'll give you an example right away. It is well known that due to the fall in income, the real estate market, in particular, housing under construction or newly built housing, began to experience serious problems. In turn, the demand for secondary housing has increased. People prefer to purchase apartments and houses at a lower price and renovate them to suit their preferences. In connection with this, the market also “rose” building materials, the production of which began to bring profits to their owners even more than in “pre-crisis” times. Laminate flooring production is one such business idea that deserves serious consideration for those entrepreneurs who are looking for an opportunity to start a serious, win-win business.
Among all kinds of floor coverings, laminate rightfully occupies one of the leading places. Why by right? Judge for yourself: the service life of even an economy class laminate is 10-12 years, and its cost is quite low; wear resistance, moisture resistance of the laminate is no less than that of other floor coverings, and the texture and appearance– much better. Few “competitive” materials can boast of such characteristics, mainly those whose cost is “off the charts”.
Brief business analysis:
Costs of setting up a business: 30 -32 million rubles
Relevant for cities with the population: without restrictions
Industry situation:average market saturation
Difficulty of organizing a business: 4/5
Payback: 1-2 years
The fact that it gained its popularity in just 15-17 years speaks in favor of laminate. That's how long he's been on Russian market building materials. However, the rest of the world has known laminate in the form in which we know it for not much longer.
For reference: the first laminate was designed by the Swedish company Pergo in 1977, but its disadvantages far outweighed its advantages to launch its large-scale production. And only 10 years later, in 1987, the German company Hornitex brought the laminate “to mind” by introducing new samples. It took another 10 years to promote the product in the West, and only a few more years later the laminate came to Russia.
Amount of investment for starting a business
It should be noted right away that the amount required to open a laminate production is quite impressive. According to the most rough estimates, this is approximately 20-23 million rubles. Moreover, this is only the cost of the production line. Add to this the rent for the production premises, the cost of the initial purchase of the necessary raw materials, and other organizational expenses.
Of course, all this is best reflected in a business plan, without which it would be simply pointless to start such a large business. You can try to write a business plan yourself, but it is better to entrust this procedure to business planning specialists. Currently, banks are very reluctant to lend to any individual business projects and startups, but if you present a truly convincing description of your future business, which has all the necessary calculations, then the chances of getting the necessary investments may still appear.
But there are also “pleasant” moments. Laminate production is considered extremely profitable business. Even a small workshop is capable of producing up to 15 million square meters per year. meters of laminate. That is, with an initial investment of 30 million rubles, and the average cost of 1 sq. m. meter of 300 rubles, the payback will be less than a year, provided, of course, competent management, the presence of permanent sales channels, and the release of high-quality products.
This is worth paying attention to
There are two main problems faced by domestic laminate manufacturers:
- Lack of suppliers of high-quality raw materials for production on the Russian market. For this reason, the necessary materials have to be purchased abroad. The raw materials offered by our few suppliers are, perhaps, only suitable for the production of an economy-class product, the share of which is only 18-19% of total sales.
- Another problem is quite ridiculous, but is quite in the “spirit” of our state. This is a complete absence of any regulations or standards for the production of laminate. Neither GOSTs for you, nor anything else. Therefore, manufacturers have to focus on foreign standards.
Business registration
First of all, it will be necessary to decide on the form of conduct entrepreneurial activity– Individual Entrepreneur or LLC. IN in this case the second option is preferable - it is unlikely that any bank will trust a large sum individual entrepreneur. The next stage is determining the tax regime of the enterprise. You can find out more about this in this.
In addition to the “standard set” of organizations when registering a business - fire service, Rospotrebnadzor, utilities, municipal administration, etc., you will have to get approval from the departments of environmental control and labor protection, because harmful substances are used in the production of laminate , in particular formaldehyde.
Selection of production premises
In general, the best option for organizing a business is to purchase any woodworking enterprise and rebuild it to suit your needs. But, if this is not possible, then you will have to either look for a room suitable for the parameters, or build it, as they say, “from scratch.”
Despite the fact that currently most laminate manufacturers are trying to focus on producing a product with moisture-resistant functions, the laminate and the raw materials for its production are “afraid” of moisture, so one of the main conditions for production premises– this means dryness, the possibility of ventilation, and the presence of a heating system.
The area of the future workshop to accommodate even a small production line must be at least 2 thousand square meters. meters, taking into account storage facilities, rooms for staff, bathrooms, etc. Finding such areas is quite difficult, and most importantly, expensive. Therefore, it is worth thinking about locating production in rural areas. Firstly, it will be much easier to find buildings that match the characteristics there. Secondly, the rent for these premises will be several times lower. Well, and finally, thirdly, inspection of production by the relevant services will be much less frequent than if located within the city limits.
Laminate production technology
Before listing exactly what equipment you will need for the full functioning of your business, you need to understand at least in general terms the production process. Laminate production technology, despite some possible differences in individual stages, includes several main stages:
Stage 1 – obtaining fiberboard:
- Wood chips, after washing and steam treatment, are crushed to the required fraction, mixed with paraffin, resins, and other binding additives that increase its moisture resistance, and dried.
- On special installation The wood chips are subjected to primary pressing, which gives it its original shape.
- On another press, the slab is finally pressed and given a perfectly smooth surface.
Stage 2 – production of laminate:
- After passing a quality check, the slab is cut into the required dimensions.
- The next stage is grinding and finishing the cut pieces.
- Pressing is repeated again.
- The penultimate stage is lamination.
- And only after this, milling is carried out - cutting locks for the laminate.
As I already noted, the technology of different manufacturers may differ slightly, but in general, everything happens exactly like this. Some manufacturers prefer to omit the first stage of production by purchasing ready-made fiberboard and making a laminate from it, spending a significant amount on this less strength and time.
Equipment for laminate production
Of course, there is no point in describing all the laminate production equipment included in the production line, because you will still be purchasing the entire set. But it doesn’t hurt to know its basic machines. This:
- Laminate cutting machine
- Lamination machine (hot press)
- Milling machine
- Packing machine
I’ll say right away that this is not all the equipment for laminate production that is necessary for full-fledged work, but only the basic one.
A few words need to be said about suppliers of raw materials for laminate production. Worthy of attention There are only three suppliers offering relatively high-quality products at reasonable prices:
- Elesgo plant in Germany
- Homanit plant - same place
- And LPK MDF in the Tyumen region
Several years ago there was another good source - the MDF plant in the Ukrainian Korosten. But after the well-known sad events, supplies from this plant to Russia stopped.
I think there is no point in writing about laminate sales channels, because for such a product, especially if it is of high quality and affordable, the buyer usually finds itself - a queue for purchases is formed even before production starts. In this regard, the crisis is not a hindrance. So, go ahead! For those who are still interested in how to conduct a competent advertising campaign, I can recommend reading the articles “The Most Effective Advertising
Laminate production technology has a number of key points, compliance with norms and rules allows you to achieve results in a short time. Laminate is produced in the form of thin sheets, their thickness is 7–11 mm, with dimensions of 1.0–1.4 m by 0.2 m. The products must be assembled by sequential connection using tenons and grooves provided along the edges.
Other types of flooring materials are also popular: parquet, carpet, linoleum, tiles. But laminated coating remains the leader due to its practicality and durability.
This is explained obvious advantages laminate over other coatings:
- Its cost is significantly lower than that of parquet, carpet or tiles.
- The coating is superior to linoleum in moisture resistance, wear resistance and abrasion resistance.
- A huge selection of textures and colors attracts not only the end consumer, but also design specialists.
Classification
Laminate classes are divided into commercial 31–34 and household 21–23. Laminated coatings home use They last no more than five years, so wear-resistant and impact-resistant material for commercial purposes is increasingly being used in everyday life. They all differ in performance properties and price.
The classification of coatings is approved by the European Union Directive, samples are tested according to the following indicators:
- strength;
- abrasion resistance;
- soundproofing properties;
- moisture resistance.
The higher the class, the better the listed properties of the laminate. Laminate coating of class 32 is guaranteed to last 15–20 years, and class 31 – 10–15 years. In addition to classes, there is such a marking as AC. It indicates the wear resistance of the coating and varies from 3 to 6.
Features of Class 31
A similar product is chosen for apartment flooring. It is better to lay it in rooms where they will be used lightly.
Characteristic indicators:
- laminate thickness from 6 to 8 mm;
- surface smoothness;
- the need for an underlying layer during installation.
The installation of such material is suitable for installing a base in a bedroom or office, where household members spend a minimum of time.
Class 32 Secrets
This type of laminate is the most preferable option for apartment floors. The coating in a residential area will last about 15 years, and for an office the service life is three times less. Product Features: 
- thickness is 7–12 mm;
- you must use a background for this class;
- resistance to cleaning agents;
- embossed, anti-slip coating;
- shockproof;
- There is a layer of wax to protect the joints from liquids.
The following classes are even more different high quality. It is important to understand for what purposes coverage is required: this will allow you not to overpay for unnecessary properties.
Technical characteristics of class 33
For heavy loads, it is worth choosing a similar laminate: its service life is 20 years, but there are other advantages: 
- Durability, resistance to abrasion, temperature, sun, moisture.
- Good sound insulation allows you to avoid the need for a substrate.
- Suitable for indoors special purpose, equipped with many electrical appliances due to their antistatic properties.
- High quality locks for assembly.
The product is suitable for office premises, apartments of large families, and pet owners.
Advantages of class 34
Durable and durable appearance, suitable for public places, especially beneficial in sports halls. Sometimes this grade comes with a lifetime warranty and is 10-12mm thick.
Advantages of class 43
This is a new product on the building materials market and has proven itself in high-use areas. Only a few manufacturers make laminate flooring. Instead of fiberboard, polyvinyl chloride (PVC) is used to make this laminate. Advantages and features:
- actively used for kitchens, balconies, bathrooms and saunas;
- high flexibility and strength;
- Manufacturers guarantee 25 years of coating service life.
The use of an underlay prior to installation of this coating is not required.
Despite long term service or a high-class product, you should use it carefully and wring out the cloth well before cleaning. If, when laying the laminate, it is impossible to install the panel due to an obstacle, then the craftsmen cut off the lock or part of it to secure the panel with special glue.
Manufacturing equipment
To produce laminate, several units of equipment are required; the main machines and mechanisms of the master include the following units:
- multifunctional sawing machine;
- special hot press;
- milling apparatus;
- mechanical packer.
In addition to the main list, there are additional units of equipment: a loader, a drying chamber. The minimum set of technical equipment will cost 1.5 million rubles.
Production technology and its features
In Europe, in the 80s of the 20th century, they began to produce laminated flooring. Laminate is a simplified, generally accepted version of the name. Now the bulk of this material is produced in Europe. Launching a laminate production line is complicated by the characteristics of the raw materials.
There are 4 layers in the structure of the laminate, they make the product durable and wear-resistant. Improvements performance characteristics achieved by increasing the layers, but the main 4 remain unchanged:
- The overlay or top layer serves to protect against the mechanical effects of operation, chemical influences, and sunlight.
- The decorative layer is a special paper or foil to imitate different structures of wood, tiles and other materials.
- The middle layer of the laminate consists of fiberboard and has good strength properties.
- The bottom layer is made of resin-impregnated or waxed paper; it protects the material from shock, abrasion and penetration of liquids.
The bottom layer is sometimes made of plastic, the total thickness of two upper layers ranges from 0.2 mm to 0.9 mm. The thickness of the bottom layer ranges from 0.1 to 0.8 mm.
There are five stages in laminate production technology:
- Production of high-density fiberboards.
- Saturation, impregnation of the surface of a product is a process called impregnation.
- Finishing the workpiece.
- Sawing
- Milling.
- Packing.
The laminated board is formed from HDF board (high-density fiberboard). There are several methods for producing laminate:
- HPL – using high pressure.
- CPL – conveyor production.
- DPL – direct pressing.
- CML or RML – continuous pressing of several layers.
- PDL – pattern printing technology.
- ELESGO is a method of drying the surface of an electron beam.
Differences in laminate production methods
With HPL technologies, materials are glued together using a cold, warm or hot method, this process is called lamination. Bonding at high temperatures allows for high quality, which is why hot lamination is often used.
Before gluing, the surface is cleaned of dust, after which glue and hardener are evenly applied. The two parts are passed through a press, gluing at a temperature of about two hundred degrees Celsius. After gluing the overlay with the decorative layer, they begin to connect this part with the base and bottom layer using glue.
The production of laminate using CPL technology is the connection of the base with the top layer through pressing. The layers are passed through rollers at high temperature. Craftsmen glue together several top layers and then press them onto an HDF board.
DPL is characterized by the absence of bonding. They take layers that have undergone the impregnation process and press them at a temperature of two hundred degrees. The resin contained in the products melts, gluing them together. After drying, a monolithic plane of the top layer of the laminate is formed.
With CML or RML methods, kraft paper is used to increase strength; this additive leads to a significant increase in the cost of the laminate.
A feature of PDL technology is decorative design, but the image is placed on a fiberboard. There is no need for additional layers of decor. Further production is carried out using DPL technology.
The top layer, consisting of paper with an image of two layers of overlay, is dried with an electron beam. ELESGO technology involves the use of acrylate resins for preliminary impregnation of the overlay. After hardening, a durable elastic film is obtained. The layers are joined with glue under pressure and at high temperature.
Is such production profitable?
Setting up laminate production is an expensive undertaking; total costs will exceed $800 thousand. In addition to the main production, it is necessary to engage in forestry and woodchip production. Such a complex enterprise is much more reliable, but the total costs will stop many businessmen.
Video: Laminate production
Laminate cannot be called a “national floor covering” - it is a premium material for finishing floors, the installation of which is suitable for almost all rooms within an apartment or private house. In addition to serving as a simple covering, laminate is an important decorative element that gives the room a richer look. It is not afraid of scratches, but is poorly resistant to water, which clearly indicates its delicacy.
A large assortment of laminate flooring from leading manufacturers in Russia, Europe and Asia puts domestic consumers in a difficult position. A huge selection, number of brands and colors can confuse anyone, even the most experienced buyer. In this regard, we have selected for you the 15 best laminate manufacturers in four main categories. Each applicant was selected taking into account the following criteria:
- brand popularity among consumers;
- recommendations from experts and professionals;
- size of assortment;
- compliance of the product price with the original quality.
All products from manufacturers included in the final rating are worthy of your priority attention.
The best European laminate manufacturers
4 HDM ELESGO
Unique production technology
Country: Germany
Rating (2018): 4.8
The HDM concern is a German company with a half-century history of development. Among its product range, the Elesgo laminate collection stands out. It is produced using patented technology, which has a number of advantages. The material is based on high-density (900 kg/m3) fiberboard, environmentally friendly (it contains no more formaldehyde than natural wood) and is resistant to mechanical impact. Characteristics of the load-bearing plate in combination with innovative locking system Unilin ensures quick installation, rigid coupling of planks and the possibility of repeated reinstallation.
However, the main difference between the technology is the application on decorative layer protective coating in the form of acrylate resin, while other manufacturers use melamine for this purpose. The difference between them is very significant: the risk of release into the atmosphere is reduced. harmful substances, the surface acquires antistatic properties and becomes more resistant to household chemicals and UV radiation. The excellent quality of Elesgo laminate is confirmed by reviews.
Advantages:
- magnificent appearance of the “mirror” coating;
- original lock connection with wax moisture-proofing impregnation;
- high mechanical strength, resistance to scratches.
Flaws:
- Like any glossy surface, it requires some care.
3 Kaindl
Best performance ability
Country: Austria
Rating (2018): 4.9
A giant from a family of German woodworking companies, whose work has been going on for more than 120 years. Kaindl Flooring GmbH is a full-cycle manufacturer: the company independently grows wood, processes the material, produces and sells products around the globe.
The company is especially loved in the USA, Canada, and other countries South America and Europe. In Russia, up to a certain point, they were neutral towards it, but the “boom” of laminate flooring brought Kaindl to the top of manufacturers here too. The only complaint about the product is the cost: the entire line of laminate flooring is priced at a high price, which is not affordable for all consumers.
Advantages:
- a large selection of laminate to suit any interior;
- use of the densest load-bearing board for laminate boards (950 kg/m3);
- The guaranteed service life of the laminate is up to 30 years.
Flaws:
- high cost.
2 Balterio
The best quality of products
Country: Belgium
Rating (2018): 4.9
The year 2001 was crowned for the Belgian industrial corporation Spanolux SA with the opening of a new division responsible for the production of promising developments of laminate flooring under the famous Balterio brand. The company's business immediately went well - helped by the systematic development of infrastructure, from the actual cultivation of wood to logistics operations. Balterio is focused on producing high quality laminates from 32 to 34 wear resistance classes in a thickness range from 7 to 12 millimeters. The cost of the entire line is quite high, but the price fully corresponds to the reliability and durability of the finishing material.
Advantages:
- wide range of products;
- large size range (length from 1192 to 2039 mm, width from 134 to 392.5 mm);
- several connection systems for the assembler level.
Flaws:
- high cost;
- products are often counterfeited by small eastern companies.
Many users are wondering which flooring to choose: laminate, parquet, tiles or linoleum. What are their main advantages and what are the main disadvantages - we find out from the comparison table.
|
Type of coverage |
Pros |
Cons |
|
Laminate |
Easy installation Several connection options: adhesive (one-piece) and glueless (detachable) Presence of antistatic agent on the surface Large selection of colors |
– Poor resistance to water – Presence of resins and toxic impregnations in the composition – Strong addiction laminate durability depending on class – High cost |
|
Parquet board |
Easy installation and subsequent cleaning High degree of durability Only “clean” materials are used in creation Installed in two ways: by gluing the boards to the base and gluing them together |
– Low variety of shades (limited only to real wood colors) – High cost |
|
Tile |
Reliable connection by laying on a concrete base Long service life Environmentally friendly Excellent moisture resistance A large number of design solutions |
– Complex installation process requiring skills and experience – High probability of injury during installation and operation – Possibility of chipping or breaking tiles |
|
Linoleum |
Installation can be carried out on almost any base Moisture resistance Good wear resistance Easy to clean Wide range of colors and designs |
– Environmentally friendly material – Poor ergonomics |
1 Pergo
The first laminate manufacturing company
Country: Sweden
Rating (2018): 5.0
A premium manufacturer of laminate, in fact, being its founder. The first batches of laminate boards rolled off the assembly line back in 1979, and even then consumers were delighted with the overall quality. Almost 40 years later, their products are still a world-class standard, which only a few have managed to achieve. Pergo production is distinguished by the strictest quality control of products at each stage of processing, which allows us to supply consumers with the best elements of flooring.
Another positive difference is the centralization and versatility of production: the laminate produced by the Belgian company is no different from what comes off the Swedish (original) assembly line.
Advantages:
- TitanX top layer protection system (effective protection against impacts, wear, abrasion and fading);
- high level of environmental friendliness;
- The guaranteed service life is 25 years.
Flaws:
- large number counterfeits on the market;
- All collections (12 lines) are very expensive.
The best Russian laminate manufacturers
4 Kronospan
Extensive range. Economy option
Country: Russia
Rating (2018): 4.2
Kronospan, one of the largest wood processing plants in Russia, under the same brand produces not only MDF and chipboard, but also laminated flooring. Reviews on it are quite contradictory, but in most cases they agree on one thing: for an economical solution, for example, finishing a rented apartment or cottage better material can't be found.
As for reliability, it strongly depends on the thickness (ranges from 7 to 14 mm) and density (800‒860 kg/m 3 and above) of the load-bearing plate. For some collections (“Titanium Prestige”, “Vintage Classic”, etc.), the manufacturer is ready to provide a guarantee of 25-30 years when used in an apartment or private house and 5 years in the industrial sector.
Advantages:
- smooth geometry of the planks and clear joining of connections;
- a wide selection of textures, gloss levels and shades to implement any design project;
- the presence of special solutions with antibacterial coating, protection against micro-scratches and built-in noise insulation - Krono Xprotect, Krono Xonic;
- hygienic certification VOC Emissions with class A+ marking (minor emission of harmful volatile substances).
Flaws:
- due to the spectacular design, you can buy it in stores at an inflated price;
- budget lines are not recommended for rooms with high traffic (office, hallway, corridor, kitchen);
- Careful preparation of the base is required before installation.
3 Tarkett
High quality combined with reasonable price
Country:
Rating (2018): 4.7
A company in which the Russian share is least visible. Tarkett was born back in 1987 as a manufacturer of carpet and vinyl coverings for floors and walls. Nowadays it is one of the largest manufacturers of laminate, the main division of which, as well as the head office, are located in Germany, while only manufacturing plants are located in Russia (place of production: the city of Mytishchi). The products produced are of high quality and reasonable prices, which are fully compensated by the reliability and durability of the products. The market is flooded with 30 collections of 32 and 33 wear resistance classes, which are very popular among users.
Advantages:
- service life varies from 15 to 25 years;
- overall product quality and reliability;
- free access to the Russian market;
- reasonable price.
Flaws:
- There are boards with defective upper and lower layers;
- Some series are characterized by poor ergonomics (slippery top layer).
2 Kronostar
Best price
Country: Germany (produced in Russia)
Rating (2018): 4.7
One of three companies (along with the Russian Kronospan and the German Kronotex) that is part of the Swiss Krono Group. It specializes in the production of a wide range of wood products for floors, walls and ceilings: from chipboard to laminate and parquet. The first batch of laminate rolled off the assembly line in 2002 Russian plant company located in the Kostroma region. The produced laminate flooring of 31-33 wear resistance classes is in stable demand, largely due to its low cost and acceptable reliability indicators.
Advantages:
- low cost;
- products strictly comply with all stated parameters;
- laminate line is distinguished by its classic soft design and a set of shades without aggressive and non-trivial solutions.
Flaws:
- uniformity of sizes across the entire line of laminate;
- defective boards come across (broken pattern, surface defect, unusable locks);
- poor design choice.
1 Ritter
The choice of professionals
Country: Russia
Rating (2018): 4.9
A fresh trend in the manufacture of laminate flooring came from where it was not expected at all. The large Russian concern RBC decided to establish the production of wood finishing materials, as a result of which the Ritter brand was founded.
Its main difference from others lies in the style of its products. Ordinary “wooden motifs” have faded into the background - the company is producing laminate with embossing to resemble natural leather. Originally, however, at first, manufacturers were faced with the question of the relevance of their development. Six years have passed, but the original laminate is still in stable demand among domestic consumers.
Advantages:
- an atypical approach to development - stylizing the surface of the laminate to look like leather;
- relative cheapness of products;
- service life is 30 years;
- exceptionally high-quality laminate of 33 and 34 wear resistance classes.
Flaws:
- no models with a smooth finish or wood-embossed finish.
The best Chinese laminate manufacturers
3 Practice
High-quality paraffin treatment of locks
Country:
Rating (2018): 4.1
Since Praktik's production facilities are concentrated in China, it would be incorrect to compare its laminate flooring with the products of German giants like HDM or Classen. But among compatriots this brand looks decent. Initially, the attention of consumers is attracted by the price of the flooring: you can buy a 12 mm thick laminate for about 900 rubles. Moreover, it is made of HDF boards with a density of 900 kg/m 3, treated with a water-repellent composition using Aquastop technology.
Additional prevention of moisture ingress is provided by impregnation of locking joints with synthetic wax. One of the buyers (by the way, a professional installer) reported on the tightness in real conditions based on his experience: after soaking the sample in water for 2 hours, the maximum change in thicknesses in several places barely reached 0.1 mm. Against this background, reviews that the material can withstand long-term use in kitchens and loggias look quite plausible.
Advantages:
- low price when using a high-quality supporting base;
- availability of domestic and foreign certificates (PEFC, ISO, EPD, Blue Angel);
- the ability to select all the necessary components (underlayment, skirting boards, thresholds) from one brand.
Flaws:
- difficulty with installation due to excessive lubrication of locks with wax;
- actual wear resistance is lower than the declared class.
2 Goodway
Original design
Country: China
Rating (2018): 4.5
This is the case when originality completely compensates for mediocrity of quality. The Goodway laminate line entered the world market as an innovator - at that time (and the matter unfolded in 2006), the solution proposed by the company looked like a very interesting and bold step. The creative genius was expressed in the creation of collections for each country separately. Thus, for England, a laminate in soft colors with light embossing was proposed, and for the Arab countries, the abundance of small elements with intricate stylization came first.
In the last few years, the production concept has changed: in order to make products more popular and accessible, China gave part of the orders (for the production of collections for Russia and Norway) to the Russian branch of the company.
Advantages:
- on at the moment seven laminate collections are produced, each with 5-12 design options;
- service guarantee – 30 years;
- product compliance with quality standards.
Flaws:
- cutting locks sometimes leaves much to be desired;
- There are some problems with the geometry of the slats.
1 Floorwood
Extensive laminate collection
Country: Germany (manufactured in China)
Rating (2018): 4.7
Nominally a Chinese company, in which the forces of the Belarusian, Russian and even Belgian sides are involved. It was the interest of a large circle of owners in mutual success that contributed to the entry of products to a good (competitive) zonal level, including the domestic domestic market.
Initially, the company was represented by only two factories, located in Germany and Belgium. Further, geography dictated that factories be located in Belarus and Russia, after which almost the entire load was transferred to Chinese production facilities. Laminate still undergoes strict quality control, but the products often have complaints from customers.
Advantages:
- abundance of model ranges and their constant updating;
- product compliance with European and Russian certifications;
- service guarantee up to 25 years.
Flaws:
- a large number of defects in Chinese units;
- the cost exceeds consumer expectations.
The best laminate manufacturers: groups of companies
4 Kastamonu
A small percentage of defects. Great service
Country: Türkiye/Russia
Rating (2018): 4.3
Kastamonu has been producing laminated floor coverings under the Floorpan trademark since 1999. During this time, the products became so popular that 10 new factories were built to produce them in different countries world, including Russia. The secret of success was originally laid down unique combination affordability, wide (about 70 various options decor) assortment and ease of installation. Among other advantages mentioned by the owners of houses and apartments where the material was used are a minimal percentage of defective lamellas and the manufacturer’s willingness to help in solving difficulties, for example, obtaining the missing quantity from a scarce collection.
The company pays special attention to the quality of the laminate: it uses high-quality wood-fiber boards, has provided protective layer 31–33 abrasion class and the presence of 4-sided chamfers. Beveled edges give finished floor expressiveness and similarity to parquet. In addition, a laminate with chamfers around the entire perimeter is considered more resistant to mechanical loads, masks cracks that occur due to temperature changes, and even helps to visually adjust the shape of the room.
Advantages:
- large selection;
- no unpleasant surprises in the form of defective parts;
- ease of installation.
Flaws:
- “dusty” effect on matte finishes;
- weakness of connecting locks.
3 Egger
User selection
Country: Austria/Germany/Russia
Rating (2018): 4.6
Egger was founded as a small manufacturer of wood materials and over 50 years has grown into a real conglomerate, uniting as many as 17 companies from all over Europe and Russia. The inexorable growth of production capacity has made it possible to expand the range of manufactured products - now Egger produces not only laminate, but also everything necessary for interior decoration and furniture manufacturing.
It is interesting that the German-Russian company produces products not only under its own brand, but also sells them, as they say, on the side. The corporation has a number of contracts signed with leading furniture manufacturers and small firms primarily engaged in product sales around the world.
Advantages:
- production of accompanying products, such as decorative profiles and cleaning products (non-aggressive for the top protective layer);
- the possibility of installing laminate on both the floor and the walls;
- The shelf life of products ranges from 12 to 25 years.
Flaws:
- in Russian series there are defective strips;
- quite high cost.
2 Quick Steps
Best price
Country: Belgium/Russia
Rating (2018): 4.8
Contrary to common sense, many people consider Quick-Step to be exclusively Belgian. It is all the more pleasant to report that the Russian division of the company is actively involved in the production of laminate under this brand.
The Belgians took a step towards popularizing and increasing the availability of products for Russian consumers. The only thing that can (and quite sufficiently) be said is that the calculation played out exactly as the manufacturers expected. The level of sales has increased, and the line of laminate flooring available for retail on the domestic market has expanded noticeably.
Advantages:
- significant expansion of the model range with the transfer of production to Russia;
- a huge selection of laminate to suit any interior;
- presence of antistatic coating;
- service life up to 25 years.
Flaws:
- Russian laminate is inferior in quality to Belgian;
- presence of a persistent chemical odor.
1 Berry Alloc
The best quality of manufactured products
Country: Belgium/Norway
Rating (2018): 4.9
The company is an important part of the transnational corporation Beaulieu International Group. It turned out as a result of the merger of the Belgian Berry Floor plant and the Norwegian company Alloc, which combined their already huge production capacities into one. The main difference (also an advantage) from other companies is the board manufacturing method: instead of standard pressing of the top layer, Berry Alloc uses HPL (High Pressure Laminate) technology. This leads to a significant increase in performance characteristics, which, judging by user reviews, really takes place. Therefore, a 30-year warranty on laminate durability easily turns into 40 - a significant increase that matters to many consumers. The company's only problem is the high cost of its products. And if for Europe this is not big problem, then in Russia things are a little different.
Advantages:
- highest quality production;
- practical service life reaches 40 years.
Flaws:
- high cost of all models in the manufacturer’s line.
How to choose a good laminate
Choice good laminate for your apartment - the matter is not as simple as it might seem initially. To ensure you don’t make a mistake with your purchase, we recommend paying attention to the following parameters:
Presence of chamfer. A chamfer is a small indentation at the ends of laminate boards. If the floor is not perfectly flat, you should give preference to a laminate with chamfers. They will visually smooth the surface by drawing the boundaries of each board. If there is no chamfer, the floor will appear monolithic.
Laminate class. Perhaps the most important indicator in this category. The lowest class of laminate boards is 31st - such a laminate, when installed in a private home, will last no more than ten years. The highest class is 34th - these boards can withstand up to 30 years of use in a private home and up to 7-15 years in commercial and crowded premises.
Decor and structure. With laminate decor, everything is simple - you should choose the most suitable color and pattern for the interior. But with the structure everything is much more interesting. There are laminate boards with a smooth surface and with embossed wood and natural leather. We recommend paying attention to corrugated models, since smooth laminate is less ergonomic for everyday use.
Board thickness. Budget laminate has an average thickness - about 8-10 millimeters. Anything smaller or larger costs much more. It is recommended to choose a thick laminate board if the room is expected to have heavy furniture or household appliances.
Moisture resistance. The maximum permissible value of moisture permeability of laminate is 18%, but in premium options this parameter is 7-12%. Accordingly, the lower the moisture permeability, the more resistant to the perception of liquids the laminate board is.
The creation of laminate dates back to the late 70s of the last century. The first flooring material that vaguely resembled modern laminate was created by Perstorp from Sweden. This company developed various materials For construction work and was quite popular throughout Europe. New material received the name laminated plastic, which means layered plastic. The first development consisted of only two parts. On top, the material was treated with melamine resin, which helped to recreate the decorative layer, and on the bottom, phenolic resins took part in the production. The layers were connected in several ways at once. Impregnation with thermoactive glue was not enough, and the creators began to use pressing under the influence of high temperatures. Laminate as we are used to seeing it appeared only a decade later. The author of the global revision of the material was the German company Hornitex. This company used a completely new technological approach and equipment to produce a new type of laminate and managed to create a laminated coating with unique properties. There were now four layers instead of two. The composition included foil impregnated in phenolic and melamine resins.
Technically speaking, laminate is just the top covering of a laminate floor panel, but we will use the common word laminate to refer to laminate flooring as a whole.
The production of laminate is a complex multi-stage process, because laminate is a multi-layer product, each layer of which is made of different materials and performs its own function. The laminate consists of four main layers, thanks to which the laminate is wear-resistant and durable. In turn, to give the laminate greater strength or other characteristics, various laminate manufacturers use more layers. But fundamentally, the remaining layers only complement the existing four layers.
Laminate device
- Top layer or overlay (from the English overlay - top layer) - designed to protect against external influences: mechanical damage, abrasion, dirt, moisture, chemicals and sun rays. It is a special transparent, high-strength film made of resin, the same “lamination” that gives the name to the entire product. The quality of the laminate depends on the quality of the overlay. The overlay may also contain transparent corundum particles, which give the topcoat additional strength.
- The decorative layer is a special paper or furniture foil that imitates the structure and color of various types of trees, ceramic tiles or other materials. The quality of this layer is such that it is sometimes difficult to distinguish laminate from products made from natural wood. In some more expensive brands of laminate, the first two layers are replaced with designer vinyl. The total thickness of all top layers can range from 0.2mm to 0.9mm.
- The middle layer is the base of the laminate. The base is made of HDF (High Density Fiber board) - a high-density fiberboard, which makes the laminate extremely strong. The middle layer can also be made of plastic to create a water-resistant laminate. The density and base material significantly influence the quality of the laminate, since their technical characteristics determine: strength, rigidity, moisture resistance and immutability geometric parameters laminate
- The bottom layer, the so-called stabilizing layer, is resin-impregnated or waxed paper, the purpose of which is to protect the HDF board from deformation and protect the laminate from moisture. Sometimes the paper is replaced with a layer of plastic. The thickness of the bottom layer ranges from 0.1mm to 0.8mm.
Laminate production technology
Making laminate is a complex process consisting of the following steps:
- production of high-density fiberboard;
- impregnation of the upper layers;
- cladding the slab;
- sawing and milling of panels;
- package.
Manufacturing High Density Fiberboard
The basis of the laminate is HDF (High Density Fiber board) - this is high-density fiberboard (from 880 kg/m3). The higher the density of the produced board, the higher the moisture resistance and mechanical strength of the laminate. The thickness of the HDF board used to make laminate can range from 5.8 mm to 12.1 mm.
The raw material for the production of HDF boards is wood, which is cleared of bark and then chopped into chips using special machines. Next, it is washed to get rid of foreign matter (dirt, sand, etc.). After washing, the wood chips are heated with steam in special bunkers to a temperature of 165 - 175°C. This is done to soften the wood chips. After heating, the wood chips become very plastic, which allows them to be crushed into fibers. Various additives and binders are added to the wood pulp crushed into fibers: resins, antiseptics, paraffin, etc. After this, the fibrous mass is dried in a dryer, at the exit of which the moisture content of the mass should not exceed 9%.
Using special units, the fibers are evenly distributed throughout set height and the width of the conveyor with a continuous carpet. After this, the carpet is pre-pressed, during which the air is squeezed out of the carpet, and its thickness is reduced by up to 7 times. After preliminary pressing, the carpet takes on the appearance of a slab. After which, the slab is subjected to basic pressing.
Moving further along the conveyor, after pressing, a continuous belt of pressed fiber is cut in width and length to the required dimensions. After this, the slabs are cooled in a special cooler for 20-25 minutes. After which the slabs are temporarily stored in stacks.
The next step after pressing the board is the process of sanding and calibrating the finished HDF board. Using special machines, the slabs are made perfectly flat and uniform in thickness.
In order to make the future laminate board moisture-resistant, some manufacturers completely impregnate the finished HDF board with moisture-repellent agents.
Impregnation of top layers
Impregnation is the impregnation of a material with special compounds. The top layers of the laminate are impregnated with resins with various additives, which form a durable layer when hardened. The strength and wear resistance of the top layer of the laminate, and therefore its class, depend on the formulation of the impregnation compositions. In some cases, corundum particles are added to the impregnation, which increases the wear resistance of the laminate.
The process of impregnation of the upper layers of the laminate is that, through a system of shafts, paper from rolls or overlays, passing through baths filled with resins with various additives, is impregnated with a solution, after which it enters the drying chamber. Thus, the upper layers are impregnated with resins, which melt when heated.
Many laminate manufacturers do not impregnate the top layers, but buy them ready-made.
Cladding of slabs
To obtain a laminated board, it is necessary to cover the HDF board with paper-resin films and an overlay. For this, there are many ways to produce laminate: HPL (High Pressure Laminate) - high pressure laminate; CPL (Continuous Pressure Laminate) – conveyor-produced laminate; DPL (Direct Pressure Laminate) – direct pressing laminate; CML (Continuous Multilayer Laminate) or RML (Reinforced Multilayer Laminate) – continuous multilayer pressing laminate; PDL (Printed Decor Laminate) – pattern printing technology; ELESGO (ELEktronen Strahl Gehaertete Oberflache) is a method of surface hardening with an electron beam.
HPL and CPL technologies
HPL technology is the very first laminate production technology. HPL technology is a lamination process - gluing two materials using glue. There are three laminating methods: cold, warm and hot. The most common is hot laminating technology, since the quality of gluing is much better.
With HPL technology, the laminating process begins with cleaning the bonded surfaces from dust. After that, hardener and glue are applied to the surface in an even layer. Next, the two bonded surfaces, at a temperature of about 200°C, are pressed together at high pressure (up to 300 MPa).
HPL technology is a two-step laminating process. At the first stage, the overlay and decorative layer are glued together. Top layers can be used, either those that have undergone the impregnation process or those that have not. If the layers have gone through the impregnation process, that is, they are already saturated with glue and dried, then the glue is not applied, and the layers are immediately pressed. During the pressing process, at high temperatures, the glue melts and sticks the surfaces together. At the second stage, to obtain a laminate, three materials are glued together at once: the resulting combined top coating, base and bottom layer.
One of the varieties of HPL technology is CPL technology, which uses conveyor presses. With this technology, passing through press rollers heated to 200°C, the top layer is rolled onto the slab. When using two or more top layers, and as a rule this is the case, these layers are similarly glued together, and only then rolled onto the HDF board.
DPL and CML technologies
The most common laminate manufacturing technology is DPL technology. With DPL technology, all layers of the laminate are simultaneously compressed at high temperatures. This laminate production technology does not use glue, since layers are used that have undergone an impregnation process, that is, impregnated with an incompletely cured melamine-containing resin, which melts during hot pressing (up to 200°C) and glues the surfaces together. Once cured, the resin and overlay become a monolithic laminate surface layer.
Some laminate manufacturers add several layers of kraft paper between the decorative layer and the base. This gives additional strength and hardness to the laminate panel. At the same time, the quality of the laminate improves, but the price also increases. This variety DPL technology, using additional layers, is called CML or RML technology.
PDL technology
With PDL technology, decorative pattern Apply directly to the HDF board. Thus, there is no need to use an additional decorative layer of paper. All other stages of production are performed using DPL technology.
ELESGO technology
ELESGO technology (ELEktronen Strahl Gehaertete Oberflache) consists of a special production of the top layer of the laminate. The top layer is made by hardening the surface under the influence of an electron beam, rather than using presses and high temperatures. The significant difference is that instead of melamine resins, acrylate resins are used.
The top layer of the laminate, with Elesgo technology, consists of three layers. To make the top layer of the laminate, the decorative layer (patterned paper) is covered with two layers of overlay impregnated with a composition of acrylate resin and mineral particles (corundum), which give the surface resistance to abrasion and scratches. After this, this three-layer sandwich is irradiated with an electron beam, under the influence of which the layers harden and form a high-strength elastic film.
Thermoactive adhesive is applied to the HDF board top and bottom, and using a press at a temperature of 200°C, all three layers of the laminate (top, base, bottom) are pressed together.
The advantages of this method are that no solvents are used, which means the laminate is more environmentally friendly. In addition, acrylate resin is antistatic and more transparent, which provides better visibility of the decorative layer.
In almost all production technologies, it is possible to produce both a smooth and structured laminate surface. The structure or smoothness of the surface is achieved by pressing the top layer. During pressing, part of the glue located on top of the overlay takes on the surface structure of the press plates. Thus, by changing the press plates, you can obtain panels with different surfaces. When producing a structural laminate surface, it is important that the structure of the press plate matches the drawing on decorative paper, and where the knot is drawn, there should be a knot relief.
More and more manufacturers are using an additional sound-absorbing layer on the underside of the panel when producing laminates. This layer prevents sound from spreading throughout your apartment. Various manufacturers laminate, used different materials as a soundproofing layer. Very often, cork is used as a soundproofing layer.
Sawing and milling of panels
The last important stage of production is the production of the laminate of the required size. Using laminate sawing equipment, laminate sheets are cut to the required dimensions. Each laminate manufacturer has its own laminate sizes. After cutting into plates, using milling equipment, a tongue and groove are cut from the edges of the laminate, with which they are fastened. Modern HDF boards allow you to cut a tongue and groove of a certain profile, which are called laminate locks. With the help of these locks, the laminate panels are tightly fastened together without the use of glue. The quality, strength and tightness of the connection of laminate panels depends on the quality of the laminate lock and the strength of the HDF sheet. Some manufacturers make laminate locks using metal or rubber inserts.
In some cases, after milling, the edges of the laminate are coated with wax compounds to protect them from moisture penetration.
After this, the surface of the laminate is cleaned and packaged using special equipment.
The laminate industry is still developing. Development is taking place in several directions, such as:
- improvement production process;
- technical improvement of laminate panels (laminate locks, sound absorption, increased strength, improved quality of laminate, water resistance of laminate, etc.);
- expansion of design refinements (colors, surface structure, laminate panel shape, etc.).
Cleaning and maintaining laminate flooring
No matter what class the chosen coating corresponds to, no matter what properties the manufacturers endow it with, improper cleaning and care can significantly shorten its service life and negate all the positive properties. The basis for the manufacture of laminate flooring is wood, which is 90% of its component. From prolonged exposure to moisture, this coating can swell, changing its structure. For proper care For laminate flooring, it is enough to use some simple rules.
For regular, scheduled cleaning, it is enough to vacuum the laminate flooring. Dirt that has stuck to the floor can be easily cleaned off with a damp, well-twisted cloth, with minimal addition of vinegar. More stubborn stains can be removed using special products. After cleaning, the floor must be wiped with a damp cloth. For a longer life of the top floor covering, try not to use detergents, which contain particulate matter. When transporting furniture, lift it off the floor; dragging may damage the covering. Whenever possible, try to use floor protection materials on the legs of chairs and tables. When cleaning using water or other water-based solutions, remember that moisture should not be absorbed into the floor.
Fashionable and relatively “young” flooring appeared in the 80s of the last century and quickly gained popularity among consumers. Despite the wide variety of textures and shades presented on the market, an increasing number of people prefer high-quality and relatively inexpensive laminated material, which is a great alternative traditional linoleum, carpet and parquet boards.
Among the main advantages of laminate are durability, ease of maintenance and a wide range of applications. This flooring is successfully used in apartments, houses and office spaces. It is a thin multilayer panel, each layer of which is made of different materials, which allows for excellent performance characteristics of the material.
When did laminate appear?
The history of laminate production goes back to 1977, when the Swedish company Pergo created the first laminated board. Of course, the product was significantly different from the coating we are used to - it consisted of two layers connected using thermoactive glue using the hot pressing method. The new material was called “laminated plastic”, and its production technology (HPL - High Pressure Laminate), which turned out to be very expensive, continued to be improved.
It took almost 10 years for another company, Hornitex, to introduce new technology laminate production - by direct pressing method (DPL - Direct Pressure Laminate). In the new product, the number of layers has increased to four, and their composition began to include foil impregnated in phenolic and melamine resins.
A little later, the German company HDM proposed a fundamentally new technology, the essence of which was to create a laminate board coated with an acrylate layer. The decorative film hardened under the influence of an electron beam, and the technology was called EOF.
In our country, laminated flooring appeared not so long ago - about 15-20 years ago. The first laminated boards were highly expensive and were inaccessible to the mass consumer. Currently, thanks to the constant improvement of laminate production technologies, new players are entering the market, offering high-quality coatings at an affordable price.
If previously all laminate production was concentrated in Europe, now you can purchase products from Asian and Russian manufacturers, which have a lower price. Traditionally, the best material is considered to be laminate made in Germany, as well as French, Belgian and Swedish. By the way, some European laminate production factories have opened their representative offices in Russia, which has made it possible to reduce the cost of the coating manufacturing process and, accordingly, offer a product in the middle and low price category. The first Russian manufacturing companies were Kronostar and Kronospan, subsidiaries of well-known European brands; they were later supplanted by brands created by domestic entrepreneurs.
Basic technologies for manufacturing laminate boards
Laminate production technologies at different factories may vary, but the principle of manufacturing laminated boards is largely similar. The first stage involves the production of high-density fiberboard, the quality of which determines the mechanical strength and moisture resistance of the future coating. The main raw material for the production of such fiberboard is steamed, crushed to the required fraction and dried wood chips. It is obtained using special machines that chop the bark-free tree into small pieces.
Resins, binders, antiseptics and paraffin are added to the material obtained in the refiner. The process of impregnating the fiberboard used to make the top layers of laminated boards is called impregnation. The future class of the finished product depends on it, because As a result of impregnation, the wear resistance and strength of the future coating increase. To impregnate the material, baths filled with a resin solution with various additives are used. The mass impregnated with it is sent to drying chambers, and then to the primary pressing unit.
There, the chipped carpet becomes almost 5-7 times thinner (the air is squeezed out of it) and takes the shape of a slab. The primary formation of the slab surface occurs at a temperature of 200-300°C and a pressure of about 300 mPa. As a result of repeated pressing, the plate is heated to 190°C under a pressure of 40-120 MPa. The final leveling of the slab surface is carried out under a pressure of 60-150 mPa.
A conveyor belt, part of a laminate production line, moves the compressed fiber to a machine where the carpet is cut into pieces according to the specified dimensions (most often 2800 x 4140 mm). In order for the slabs to acquire a stable structure, they are placed in a special cooler for 20-30 minutes, after which they are stacked for several days.
Next, the pressed boards are sent to a formatter - equipment for laminate production, which cuts the workpiece in half and polishes it, making the surface perfectly smooth and the thickness equally even. To obtain a moisture-resistant laminate, some manufacturers impregnate the resulting board with special moisture-repellent agents.
At the next stage, the blanks are sent to the pressing area, where they are covered with paper-resin films and an overlay (from the English overlay - top layer). As already mentioned, today manufacturers use several laminate production technologies, or rather technologies for connecting individual layers to each other.
The most common is the DPL method, according to which all layers of the laminate are pressed together simultaneously under the influence of high temperatures. The use of glue is not intended, since the layers impregnated with a resin solution are transformed into a single monolithic surface of the board during the hot pressing process. If additional layers of kraft paper are used, then this technology is called CML or RML.
PDL pressing technology allows you to apply a decorative design directly to the board, which eliminates the need for a top decorative layer of paper. Otherwise, the PDL technology repeats the previously described steps.
If manufacturers use ELESGO technology, the main difference from previous pressing methods is the overlay hardening process. Coated with acrylate resin, it is exposed to an electron beam. The final product is considered more environmentally friendly, and the clearer acrylate resin allows for better visibility of the top layer.
Special machines for laminate production make it possible to produce boards with both a smooth and structured surface that follows the relief of natural wood. Using sawing devices, the pressed panels are cut into elements, then tenons and grooves (laminate locks) are cut out, which allow the individual flooring boards to be fastened together and are lubricated with a wax coating that prevents moisture from getting inside. At the final stage of the production process, the boards are packed into bundles and sent to the warehouse.
Despite the presence of seemingly well-developed production technologies laminated coating, experts never tire of improving them, offering even higher quality, durable and moisture-resistant material with improved sound-absorbing properties. In addition, work continues on the creation of new forms, original patterns and textured surfaces of laminate boards, which reduces the existing differences between natural parquet, tiles and laminate to almost a minimum.